Shipping container for mail cartons

ABSTRACT

A master shipping container for a plurality of material handling cartons formed from a single plank of cut and scored fiberboard so as to have secure, weathertight top and bottom end closures which can readily be opened. External closure flaps on the end closures are held in place by strap segments of a carrying harnass extending around the outside of the container.

United States Patent 1191 Bruckner et a1.

SHIPPING CONTAINER FOR MAIL CARTONS Washington, D.C.; Liberity Carton Service, Minneapolis, Minn.

Filed: Jan. 17, 1914 Appl. No.: 434,211

U.S. C1 229/38; 229/46 Int. Cl. B651) 5/08 Field of Search. 224/45 F, 45 H, 45 C, 45 BA;

229/38 R, 39 R, 46 R; 190/59; 294/77 References Cited UNlTED STATES PATENTS 6/1885 Birley 229/38 1 1/1899 Morgan 9/1912 Smith 229/38 1 1 Oct. 21, 1975 1,184,689 5/1916 Houghland 229/38 1,495,669 5/1924 Burkholder 229/46 1,539,677 5/1925 Labombarde 229/38 1,682,179 8/1928 Krembs 229/46 1,838,269 12/1931 Langford et a1. 229/38 2,186,777 1/1940 Best 229/39 2.706.591 4/1955 Sheard 229/39 3,120,334 2/1964 Schill 229/38 FORElGN PATENTS OR APPLICATIONS 418,457 9/1910 France 229/46 Primary Examiner-Frank E. Werner Assistant ExaminerKenneth Noland Attorney, Agent, or Firm-Williamson, Bains & Moore [5 7] ABSTRACT A master shipping container for a plurality of material handling cartons formed from a single plank of cut and scored fiberboard so as to have secure, weathertight top and bottom end closures which can readily be opened. External closure flaps on the end closures are held in place by strap segments of a carrying harnass extending around the outside of the container.

3 Claims, 6 Drawing Figures U.S. Patent Oct. 21, 1975 SHIPPING CONTAINER FOR MAIL CARTONS BRIEF SUMMARY OF THE INVENTION The shipping container of this invention is particularly characterized by its lightweight, easily assembled, construction features, which, coupled with its tight, secure end closures and ease of handling make it particularly suitable for shipping and handling mail. The container is particularly designed to serve as a master shipper in which a predetermined number of closed mail trays of the type disclosed in our copending US. patent application, Ser. No. 406,692, filed on Oct. 15, 1973, may be transported by plane, train, or truck between cities.

These basic advantages are realized by forming the container from a single plank of fiberboard material cut and scored in a predetermined manner so as to be foldable into the shape of a substantially rectangular container having top and bottom end closures which are very secure and weathertight and which can be opened and closed easily.

The aforesaid end closures preferably each comprise a hinged cover panel which is attached at its opposite ends to the opposed side walls of the container by segmented gusset panels which are scored so as to collapse inwardly and provide a tight closure at the opposite ends of the cover panels when they are folded inwardly to closed positions. Substantially weathertight end closures are obtained by further providing inner closure panels hingedly attached to the top and bottom edges of the front wall of the container and foldable inwardly under the aforesaid cover panels over the top and bottom end of the container.

A particular advantageous feature of the container end closures resides in the use of external closure flaps hingedly attached to the front edges of the aforesaid cover panels and folded over the outside face of the container front wall in overlying relation thereto at its top and bottom ends when the cover panels are closed.

As a further beneficial feature, the container is placed within a carrying harness having a plurality of straps embracing the container, with one or more of the straps serving to hold the aforesaid cover panels in their inwardly folded, closed positions.

These and other objects and advantages of our invention will be readily apparent as the following description is read in conjunction with the accompanying drawings wherein like reference numerals have been used to designate like elements throughout the severals views.

BREIF DESCRIPTION OF THE DRAWINGS FIG. 1 is a plan view of the cut and scored fiberboard plank from which the container of this invention is constructed;

FIG. 2 is a perspective view showing the container folded to an intermediate state of assembly; v

FIG. 3 is a fragmentary, perspective view showing one of the end closures prior to final closing;

FIG. 4 is a perspective view of the fully folded and assembled container having a carrying harness thereon;

FIG. 5 is a bottom, plan view of the fully assembled container of FIG. 4; and

FIG. 6 is a perspective view of a modified form of carrying harness.

DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring now to the drawings, we have shown in FIG. I the cut and scored blank of fiberboard material from which the shipping container of this invention is formed. It is to be noted that it is not necessary that the container be constructed from fiberboard. Other types of strong, bendable material may be used. The blank of fiberboard material is generally designated by reference numeral 1 and is comprised ofa plurality ofpanels interconnected along scored fold lines. The panel forming the rear wall of the container is designated by reference numeral 2, and is connected to a pair of side wall panels 4 and 6 along scored fold lines 8 and 10 defining its opposite vertical edges when the container is fully assembled. Front wall panel 12 is hingedly attached to the outermost edge of side panel 4 along a scored, fold line connection 14 therewith. It will thus be seen that side wall panel 4 is hingedly connected between longitudinal edge 8 of rear wall 2 and longitudinal edge I4 of front wall 12 along fold line connections therewith. A tuck flap ]6 formed on the outer, free end of front panel 12 as shown in FIG. 1 is utilized to form a seam joint with the free outer edge 60 of side wall panel 6 in the course of forming the container from fiberboard blank 1.

As may be noted by reference to FIG. 2, side walls 4 and 6 and front wall 12 are folded along scored fold lines 8, l0 and 14 to form a container of generally rectangular configuration. Flap 16 on the outer end of front wall 12 is tucked inside of the adjoining edge 6a of side wall 6 and is attached thereto by means of staples 18 or other appropriate means to form a seam. The folding of the side walls and front wall in the aforesaid manner brings longitudinal edge 12a of front wall 12, to which tuck flap 16 is attached, and longitudinal edge 60 of side wall 6 together along the stapled seam between front wall 12 and side wall 6.

The top and bottom ends of the container are closed by substantially identical end closures. The bottom end closure is comprised of a bottom cover panel 20 hingedly attached to the bottom edge of rear wall panel 2 along fold line 22 and a pair of gusset panels 24 and 32 on opposite sides thereof. Gusset panel 24 is comprised of two foldable panel segments 24a and 24b joined together along fold line 26; and gusset panel 24 extends between and is attached to side wall panel 4 and bottom closure panel 20 along fold line connections 28 and 30 therewith. Gusset panel 32 is attached to the opposite side of bottom closure panel 20 and is likewise comprised of two panel segments 32a and 32b joined together and foldable along scored fold line 34. Gusset panel 32 extends between the opposite edge of closure panel 20 and the adjoining bottom edge of side wall 6 and is attached thereto along fold line connections 36 and 38 as shown in FIG. 1. An outer closure flap 40 is hingedly attached to the outer edge of bottom closure panel 20 along fold line connection 42 therewith, and is utilized to provide a portion of the end closure in a manner hereinafter explained.

The top end closure likewise comprises a cover panel 44 hingedly attached to the top edge of rear wall panel 2 along fold line connection 46 therewith. Gusset panels 48 and 56 are provided on opposite sides of top cover panel 44. Gusset panel 48 is comprised of two foldable panel segments 48a and 48b joined together along fold line 50. Fold line connections 52 and 54 serve to attach gusset panel 48 between the top edge of side panel 4 and one side edge of top cover panel 44. The two foldable panel segments 56a and 56b of gusset panel 56 are joined together along fold line connection 58; and gusset panel 56 is attached along fold line connections 60 and 62 with the top edge of side wall panel 6 and one edge of top cover panel 44, respectively.

Each of the gusset panels 24, 32, 48 and 56 is of triangular shape as shown in FIG. 1; and each of the dividing score lines 26, 34, 50 and 58 extend from the point of intersection of the inner two side edges of each gusset panel and the opposite, third side edge of each of the gusset panels. This gusset panel construction not only strengthens the end closures, but also assists in providing tight, secure, substantially weather impervious end closures.

Hingedly attached to the front edge of top cover panel 44 along a fold line connection 65 therewith is an outer closure flap 64. This outer closure flap 64 functions to provide a weather-tight joint along the front edge of the top end closure as explained below.

Each of the top and bottom end closures further comprises an inwardly foldable closure panel. Inner closure panel 66 for the bottom end closure is hingedly attached to the bottom edge of front wall panel 12 along fold line connection 67 therewith, and is provided with a finger notch 68 in its outer edge to permit it to be easily gripped and pulled open. Outer closure panel 70 for the top end closure is hingedly attached to the top edge of front wall panel 12 along fold line connection 71 and is likewise provided with a finger notch 72 on its opposite peripheral edge.

With the container in the open-ended rectangular configuration shown in FIG. 2, the bottom end is closed by first folding inner closure panel 66 upwardly and inwardly along its fold line 67 to a position overlying the bottom end of the container. Inner closure panel 66 is sized to fit snugly over the bottom end of the container defined by the bottom edges of the rear, front and side walls 2, l2, 4 and 6. Next, bottom cover panel is folded upwardly and inwardly over inner closure panel 66. This will cause gusset panels 24 and 32 to collapse inwardly along their fold lines 26 and 34, thereby tightly closing the opposite ends of the bottom end of the container. When bottom cover panel 20 is folded to the aforesaid closed position, its outer closure flap 40 is folded over the outside face of the bottom end of front wall 12 in upwardly extending, overlying relation thereto as shown in FIG. 4.

The top end of the container is closed in the same manner. Inner closure panel 70 is first folded inwardly and downwardly over the top end of the container in the manner shown in FIG. 1. Then, top cover panel 44 is folded downwardly and inwardly in overlying relation to panel 70. As this is done, gusset panels 48 and 56 attached to top cover panel 44 collapse inwardly in the manner shown in FIG. 3 to form a tight, substantially weather impervious closure along the opposite ends of the top of the container. Top closure flap 64 is maintained outside of the top end of front wall 12, and with cover panel 44 in its downwardly folded, closed position, closure flap 64 will be disposed in a downwardly folded position over the outside face of the top end of front wall 12 in overlying relation thereto. Top cover panel 44 and closure flap 64 are shown in their closed position in FIG. 4.

For the purpose of carrying the container, and to assist in holding the top and bottom cover panels 20 and 44 closed, the container is placed within a carrying harness generally indicated by reference numeral 74 in FIG. 4. Harness 74 assumes a basket-like configuration in embracing relation to the container and is comprised of a plurality of interconnected straps. Two generally U-shapcd straps 76 and 78 extend vertically around the side and oppositely facing front and bottom walls of the container. As may be noted with respect to FIG. 5, U- strap 76 has a bottom segment 76a which extends around the bottom of the container and a pair of opposed legs which extend upwardly over the container side walls 4 and 6. U-strap 78 has a bottom segment 78a extending around the bottom of the container and crossing strap segment 76a as shown in FIG. 5. Strap segment 76a and 78a are attached to each other by stitches or other appropriate means at their point of intersection. The side legs of strap 78 extend upwardly over the front and back walls 12 and 2 of the container. Strap 78 is comprised of strap segments 78a, 78b, and 78c. Strap segment 78b extends over top cover panel 44 and has a double ring clasp 79 of known construction attached thereto. The harness is tightly secured to the container by extending strap segment 78c of strap 78 through ring clasp or buckle 79 and pulling it tight in a known manner. Harness 74 further comprises a pair of straps 80 and 82 which embrace the container in horizontal planes and are attached to straps 76 and 78 at their points of intersection therewith. Strap carrying handles 84 are attached to the opposite ends of upper horizontal strap 80 along the segment thereof overlying side walls 4 and 6 for the purpose of carrying the container. Only one of such strap handles 84 is shown in FIGS. 3 and 4. inner closure It is to be noted that vertical strap 78 extends completely around the outer periphery of the container over both bottom end cover panel 20 and top end cover panel 44. Thus, when strap 78 is buckled as shown in FIG. 4, it serves to hold bottom and top cover panels 20 and 44 and their respective closure flaps 40 and 64 tightly against the container in their downwardly folded, closed positions in the manner shown in FIG. 4. Closure flaps 40 and 64 cooperate with the respective, inner closre panels 66 and to provide tight, secure, substantially weather-proof closures along the front edges of the container at its top and bottom ends.

In actual use, the bottom end of the container will be closed prior to placing the container within carrying harness 74. Harness 74 is slipped over the bottom end of the container and pulled upwardly thereover utilizing carrying handle straps 84. After loading the container with a plurality of closed mail trays or cartons, the top end closure is closed in the aforesaid manner, with top cover panel 44 being folded to its downwardly disposed, closed position after closure panel 70 is folded inwardly underneath it. Strap ends 78!) and 78c are then pulled tightly together utilizing buckle or clasp 79, with the result that end cover panels 20 and 44 are tightly secured in their closed positions.

Although the top and bottom end closures of the container have been described as being identical, it is anticipated that the bottom closure, for example, could take a different form. Having opposite ends which can be readily opened facilitates collapsing the fiberboard container to a flattened condition for compact storage when it is not being used.

In FIG. 6 we have shown an alternative form ofa carrying harness generally designated by reference numeral 88 for use with relatively larger containers. Harness 88 also has a basket-like configuration comprised of two, main U-shaped straps 90 and 92. The bottom segment 90a of strap 90 extends across the two bottom support segments 92a and 92b of strap 90 and is attached thereto as shown in FIG. 6. The pairs of upwardly extending segments of strap 92 which extend over the front and rear wallsof the container shown in phantom lines in FIG. 6 provide good support over the larger area wall faces of such a container Strap segments 92c extend over the front wall of the container and are brought together in a generally V-shape d configuration, from which extends a top closing strap segment 92f. Rear wall strap segments 92d come together in a V-shaped configuration over the top of the container, and have a top connecting strap end 92c attached to their forward end. A double ring buckle or clasp 98 is attached to strap end 922; and harness 88 is tightly secured to the container by pulling strap end segment 92f tightly through buckle 98. Two vertically spaced horizontal straps 94 and 96 completely embrace the container and are sewed or otherwise connected to vertically extending straps 90 and 92 at their point of intersection therewith. Carrying handles 95 are provided on the opposite ends of upper, horizontal strap 94 as shown.

Those skilled in the art will readily appreciate that the container described herein is strong, relatively lightweight, and substantially weatherproof when the end closures as described above are tightly closed by the carrying harness. We anticipate that various changes can be made in the size. shape and manner of construction of the shipping container without departing from the spirit and scope of our invention as defined by the following claims.

What is claimed is:

l. A material handling container formed from a single blank of cut and scored fiberboard, and comprising:

a pair of opposite, upright front and rear walls;

a pair of opposite, upright side walls extending between said front and rear walls at substantially right angles thereto from fold line connections with at least one of said front or rear walls and cooperating therewith to define a substantially rectangular container;

a bottom end closure wall closing the bottom end of said container;

at top end closure for said container comprising a cover panel hingedly attached along one longitudinal edge thereof to the top edge of said rear wall by a fold line connection therewith, whereby said cover panel is foldable downwardly over the top end of said container to a closed position, and a closure flap hingedly attached to the front edge of said cover panel along a fold line connection therewith, said closure flap being disposed in a downwardly folded position over the outside face of the top end of said front wall when said cover panel is in said closed position; and strap carrying harness embracing said container and having at least one strap extending completely, vertically around said container lengthwise of said front and rear walls, and at least one additional strap extending horizontally, completely around the upper end of said container generally at right angles to said vertically extending strap and having carrying handles on opposite end portions thereof, said vertically extending strap having a pair of releasably engagable end segments attached to said horizontal strap at their lower ends on opposite sides of said container and extending freely upwardly from said points of attachment over said cover panel and said closure flap and secured together to hold said top end closure in its closed position.

2. A material handling container as defined in claim 1 wherein:

said bottom end closure wall comprises a cover panel hingedly attached along one longitudinal edge thereof to the bottom edge of said rear wall by a fold line connection therewith, whereby said bottom cover panel may be folded inwardly to a closed position to close the bottom end of said container, and a closure flap hingedly attached to the front edge of said bottom cover panel along a fold line connection therewith, said bottom closure flap being disposed in an upwardly folded position over the outside face of the bottom end ofsaid front wall when said bottom cover panel is in said closed position; and

said one strap extends vertically around said container lengthwise of said front and rear walls, and embraces said bottom cover panel and its closure flap as well as said top closure panel and serves to hold both said top end closure and said bottom end closure closed.

3. A collapsible. material handling container formed from a single blank of cut and scored fiberboard. and comprising:

a pair of opposite, upright front and rear walls;

a pair of opposite, upright side walls extending between said front and rear walls at substantially right angles thereto and cooperating therewith to define a substantially rectangular container, one of said side walls being hingedly connected between one longitudinal edge of said rear wall and one longitudinal edge of said front wall along fold line connections therewith, and the other one of said side walls being hingedly connected along one of its longitudinal edges to the opposite longitudinal edge of said rear wall along a fold line connection therewith, and the other longitudinal edge of said front wall and said other one of said side walls being joined together along a seam therebetween, said side walls and said front wall being folded into a rectangular configuration along said fold line connections therebetween to bring said other longitudinal edge of said front wall and said other side wall together at said seam; bottom end closure wall closing the bottom end of said container; and top end closure for said container comprising; a cover panel hingedly attached along one longitudinal edge thereof to the top edge of said rear wall by a fold line connection therewith, and a pair of triangular gusset panels at opposite ends of said cover panel, each of said gusset panels having the inner two side edges thereof hingedly attached at the top edge of one of said side panels and the adjacent end edge of said cover panel along fold line connections therewith. and each of said gusset panels being divided into two inwardly foldable panel segmerits by a score line extending between the point of intersection of said inner two side edges and the third side edge thereof, whereby each of said gusset panels will collapse inwardly when said cover panel is swung downwardly to a closed position against the top of said front, rear and side walls to form a tight, impervious closure along the opposite ends of the top of the container.

an inner closure panel hingedly attached along one longitudinal edge thereof to the top edge of said front wall along a fold line connection therewith, said closure panel being folded inwardly under the inwardly collapsed gusset panels and under said cover panel in coextensive relation thereto over the top end of said container when said top end closure is fully closed;

a closure flap hingedly attached to the front edge of said cover panel along a fold line connection therewith, said closure flap being disposed in a downwardly folded position over the outside face of the top end of said front wall when said cover panel is in said closed position; and

strap carrying harness embracing said container and having at least one strap extending completely, vertically around the periphery of said container lengthwise of said front and rear walls, and at least one additional strap extending horizontally, completely around said container, said vertically extending strap having a pair of releasably engagable end segments attached to said horizontal strap segment at their lower ends on opposite sides of said container and extending freely, upwardly from said points of attachment over said cover panel and said closure flap and secured together to hold said top end closure in its closed position.

I =8 i I 

1. A material handling container formed from a single blank of cut and scored fiberboard, and comprising: a pair of opposite, upright front and rear walls; a pair of opposite, upright side walls extending between said front and rear walls at substantially right angles thereto from fold line connections with at least one of said front or rear walls and cooperating therewith to define a substantially rectangular container; a bottom end closure wall closing the bottom end of said container; a top end closure for said container comprising a cover panel hingedly attached along one longitudinal edge thereof to the top edge of said rear wall by a fold line connection therewith, whereby said cover panel is foldable downwardly over the top end of said container to a closed position, and a closure flap hingedly attached to the front edge of said cover panel along a fold line connection therewith, said closure flap being disposed in a downwardly folded position over the outside face of the top end of said front wall when said cover panel is in said closed position; and a strap carrying harness embracing said container and having at least one strap extending completely, vertically around said container lengthwise of said front and rear walls, and at least one additional strap extending horizontally, completely around the upper end of said container generally at right angles to said vertically extending strap and having carrying handles on opposite end portions thereof, said vertically extending strap having a pair of releasably engagable end segments attached to said horizontal strap at their lower ends on opposite sides of said container and extending freely upwardly from said points of attachment over said cover panel and said closure flap and secured together to hold said top end closure in its closed position.
 2. A material handling container as defined in claim 1 wherein: said bottom end closure wall comprises a cover panel hingedly attached along one longitudinal edge thereof to the bottom edge of said rear wall by a fold line connection therewith, whereby said bottom cover panel may be folded inwardly to a closed position to close the bottom end of said container, and a closure flap hingedly attached to the front edge of said bottom cover panel along a fold line connection therewith, said bottom closure flap being disposed in an upwardly folded position over the outside face of the bottom end of said front wall when said bottom cover panel is in said closed position; and said one strap extends vertically around said container lengthwise of said front and rear walls, and embraces said bottom cover panel and its closure flap as well as said top closure panel and serves to hold both said top end closure and said bottom end closure closed.
 3. A collapsible, material Handling container formed from a single blank of cut and scored fiberboard, and comprising: a pair of opposite, upright front and rear walls; a pair of opposite, upright side walls extending between said front and rear walls at substantially right angles thereto and cooperating therewith to define a substantially rectangular container, one of said side walls being hingedly connected between one longitudinal edge of said rear wall and one longitudinal edge of said front wall along fold line connections therewith, and the other one of said side walls being hingedly connected along one of its longitudinal edges to the opposite longitudinal edge of said rear wall along a fold line connection therewith, and the other longitudinal edge of said front wall and said other one of said side walls being joined together along a seam therebetween, said side walls and said front wall being folded into a rectangular configuration along said fold line connections therebetween to bring said other longitudinal edge of said front wall and said other side wall together at said seam; a bottom end closure wall closing the bottom end of said container; and a top end closure for said container comprising; a cover panel hingedly attached along one longitudinal edge thereof to the top edge of said rear wall by a fold line connection therewith, and a pair of triangular gusset panels at opposite ends of said cover panel, each of said gusset panels having the inner two side edges thereof hingedly attached at the top edge of one of said side panels and the adjacent end edge of said cover panel along fold line connections therewith, and each of said gusset panels being divided into two inwardly foldable panel segments by a score line extending between the point of intersection of said inner two side edges and the third side edge thereof, whereby each of said gusset panels will collapse inwardly when said cover panel is swung downwardly to a closed position against the top of said front, rear and side walls to form a tight, impervious closure along the opposite ends of the top of the container, an inner closure panel hingedly attached along one longitudinal edge thereof to the top edge of said front wall along a fold line connection therewith, said closure panel being folded inwardly under the inwardly collapsed gusset panels and under said cover panel in coextensive relation thereto over the top end of said container when said top end closure is fully closed; a closure flap hingedly attached to the front edge of said cover panel along a fold line connection therewith, said closure flap being disposed in a downwardly folded position over the outside face of the top end of said front wall when said cover panel is in said closed position; and a strap carrying harness embracing said container and having at least one strap extending completely, vertically around the periphery of said container lengthwise of said front and rear walls, and at least one additional strap extending horizontally, completely around said container, said vertically extending strap having a pair of releasably engagable end segments attached to said horizontal strap segment at their lower ends on opposite sides of said container and extending freely, upwardly from said points of attachment over said cover panel and said closure flap and secured together to hold said top end closure in its closed position. 